light MITSUBISHI MONTERO 1991 Owner's Guide

Fig. 19: 1991 Cruise Control Switch Connector
Courtesy of Mitsubishi Motor Co.
Fig. 20: 1991 Stoplight Switch Connector
Courtesy of Mitsubishi Motor Co.

Test No. 5 (Vehicle Speed Sensor Circuit)
When vehicle moves slowly, 0-2 or more volts should alternate
at terminal No. 19 of cruise control unit. If circuit does not test
correctly, replace sensor as necessary or repair harness.
Test No. 6 (Vacuum Pump Circuit)
1) When cruise system is in deceleration or release mode,
battery voltage should be present on terminals No. 26 and 13 of cruise
control unit. If circuit does not test correctly, replace vacuum pump
as necessary or repair harness.
2) When cruise system is in release mode, battery voltage
should be present on terminal No. 12 of cruise control unit. When
cruise system is in hold mode, voltage on terminals No. 12, 13 and 26
will go from battery voltage to zero volts depending on driving
conditions. If circuit does not test correctly, replace vacuum pump as
necessary or repair harness.
Test No. 7 (Stoplight Switch Circuit)
When brake pedal is pressed, battery voltage should be
present on terminal No. 15 of cruise control unit. If voltage is not
present, adjust or replace brake switch. If circuit does not test
correctly, replace switch as necessary or repair harness.
Test No. 8 (Clutch Switch Circuit)
When clutch pedal is pressed, battery voltage should be
present at terminal No. 1 of cruise control unit. If circuit does not
test correctly, replace switch as necessary or repair harness.
Test No. 9 (Inhibitor Switch Circuit)
When transmission is in Neutral position, battery voltage
should be present on terminal No. 1 of cruise control unit. If circuit
does not test correctly, replace switch as necessary or repair
harness.
Test No. 10 (Overdrive Switch Circuit)
When overdrive switch is pushed to ON position, battery
voltage should be present on terminal No. 11 of cruise control unit.
If circuit does not test correctly, replace switch as necessary or
repair harness.
Test No. 11 (Idle Switch & Throttle Position Sensor Circuit)
1) When accelerator pedal is pressed, 4.5-5.5 volts should be
present on terminal No. 4 (idle switch) of cruise control unit. When
accelerator pedal is released, voltage should not be present on
terminal No. 4 of cruise control unit.
2) When accelerator pedal is pressed to wide open throttle,
4.0-5.5 volts should be present on terminal No. 5 (throttle position
sensor) of cruise control unit. When accelerator pedal is released, .
5-.7 volts should be present on terminal No. 5 of cruise control unit.
If circuit does not test correctly, replace sensor as necessary or
repair harness.
Fig. 22: 1992 Cruise Control Unit Connector
Courtesy of Mitsubishi Motor Co.

Fig. 23: 1992 Main Cruise Control Switch Connector
Courtesy of Mitsubishi Motor Co.
Fig. 24: 1992 Stoplight Switch Connector
Courtesy of Mitsubishi Motor Co.

Replace cruise control switch if it does not test correctly.
Main Switch (1992)
1) In each switch position, continuity should be present
between terminals No. 2 and 7 for switch illumination. See Figs. 22-
29. When switch is moved to Neutral position, continuity should be
present between terminals No. 1 and 4.
2) When switch is moved to ON position, continuity should be
present between terminals No. 1, 4 and 5. Connect battery voltage to
terminal No. 5 and ground terminal No. 4.
3) Battery voltage should then be present on terminal No. 1
when main switch is moved to On position. Replace switch if it does
not test correctly.
BRAKELIGHT/STOPLIGHT SWITCH TEST
Disconnect switch connector. When brake pedal is pressed,
continuity should be present between terminals No. 2 and 3. See
Figs. 22 -29. When brake pedal is released, continuity should be
present between terminals No. 1 and 4. Replace switch if it does not
test correctly.
IDLE SWITCH & THROTTLE POSITION SENSOR TESTS
Throttle Position Sensor (1992)
1) Disconnect sensor connector. Resistance between terminals
No. 1 and 4 should be 3500-6500 ohms. Use an analog ohmmeter to
measure resistance between terminals No. 1 and 3. See Figs. 22-29.
2) Slowly open throttle valve to wide open throttle.
Resistance should change smoothly as throttle is opened. Replace
throttle position sensor if it does not test correctly.
Idle Switch (1992)
1) Disconnect throttle position sensor connector. Continuity
should be present between terminals No. 1 and 2 with accelerator pedal
released. See Figs. 22-29. Continuity should not be present with
accelerator pedal pressed.
2) If continuity is not present with accelerator released,
loosen throttle position sensor mounting screw. Turn throttle position
sensor completely clockwise. Recheck continuity. Replace throttle
position sensor if idle switch does not test correctly.
INHIBITOR SWITCH TEST
Disconnect switch connector. Shift transaxle into Neutral and
Park positions. On 1991 models, continuity should be present between
Black/Yellow wire terminals No. 3 and 4. On 1992 models, continuity
should be present between terminals No. 7 and 12. See Figs. 22-29. On
all models, if continuity is not present, adjust inhibitor switch. If
switch is adjusted properly, replace switch.
VACUUM PUMP TEST
1992
1) Remove vacuum pump connector. Resistance should be 50-60
ohms between terminal No. 1 and terminals No. 2 and 3. See Figs. 22-
29. Ensure solenoid valve makes operating noise when battery voltage
is applied between terminal No. 1 and terminals No. 2 and 3.
2) If solenoid valve does not make noise, replace vacuum pump
assembly. Apply battery voltage to terminals No. 1 and 4, motor should
operate. Replace vacuum pump if motor does not operate.

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DEFO GGER - R EA R W IN DO W

1991 M it s u bis h i M onte ro
1991 ACCESSORIES & SAFETY EQUIPMENT
Chrysler Corp./Eagle/Mitsubishi Defoggers - Rear Window
Dodge; Colt, Colt Vista, Colt 200, Stealth
Eagle; Summit
Mitsubishi: Eclipse, Galant, Mirage, Montero, 3000GT
Plymouth; Colt, Colt Vista, Colt 200
DESCRIPTION & OPERATION
The rear window defogger is a heating wire grid bonded to the
inside of the window. Heat is regulated by a control switch located on
the instrument panel.
TROUBLE SHOOTING
DEFOGGER DOES NOT WORK
Check for blown fuse, poor contact, defective defogger
switch, poor connection or open wire.
INDICATOR LIGHT DOES NOT WORK
Check for burned out bulb, open wire or poor connection.
TESTING
NOTE: Testing information for all components on all vehicles is
not available from manufacturer.
DEFOGGER SWITCH TEST
NOTE: Remove window defogger switch and disconnect switch
connector for the following test.
Colt, Colt 200, Mirage & Summit
Turn defogger switch to OFF position. Check switch continuity
using ohmmeter. Continuity should be present between terminals No. 3
and 6. See Fig. 1. Turn defogger switch to ON position. Continuity
should be present between terminals No. 1 and 5, 2 and 4, and 3 and 6.
Colt Vista
Turn defogger switch to OFF position. Check switch continuity
using ohmmeter. Continuity should be present between terminals No. 3
and 6, and terminals No. 4 and 1. See Fig. 1. Turn defogger switch to
ON position. Continuity should exist between terminals No. 5 and 2, 3
and 6, and 4 and 1.
Eclipse
Turn defogger switch to OFF position. Check switch continuity
using ohmmeter. Continuity should be present between terminals No. 1
and 5, and terminals No. 2 and 6. Turn defogger switch to ON position.
Continuity should be present between terminals No. 3 and 4, 1 and 5,
and 2 and 6. See Fig. 1.
Galant
Turn defogger switch to OFF position. Check switch continuity

Colt, Colt 200, Mirage & Summit
Remove defogger timer from junction block under left side of
instrument panel. Connect a battery and test light to defogger timer
terminals. See Fig. 3. Apply battery voltage to terminal No. 7 for 5-7
seconds. Ensure test light illuminates for approximately 10 seconds.
Reapply battery voltage to terminal No. 7. Test light should go off
when voltage is applied again.
Colt Vista
With ignition switch in ON position, apply battery voltage to
terminal No. 2 of defogger timer. Timer should operate for
approximately 11 seconds then stop. See Fig. 3.
Eclipse & Galant
Remove defogger timer from interior relay block. Connect
battery voltage and test light to timer. See Fig. 3. Ensure test light
illuminates for approximately 11 seconds when battery voltage is
applied to terminal No. 4. Reapply battery voltage to terminal No. 4
and observe test light. Test light should go off.
Fig. 3: Identifying Defogger Timer Terminals
Courtesy of Chrysler Motors.
GRID TEST
1) Start engine and operate at 2000 RPM. Ensure battery is
fully charged. Turn defogger switch to ON position. Using a voltmeter,
check voltage at center section of each grid wire. If voltage is
approximately 6 volts, grid wire is okay. If voltage is approximately
12 volts, an open is present in the negative circuit. Move probe
slowly toward the negative terminal to determine location of open
circuit.
2) If voltage is zero volt, an open is present in the
positive circuit. Move probe slowly toward the positive terminal to

of shaft to prevent boot damage during removal.
3) Remove DOJ boot. Note size of boot. Remove dust cover from
shaft. Straighten BJ boot protector and remove protector band. Move
boot protector toward BJ side of shaft and remove. Remove BJ boot.
CAUTION: Drive axle and BJ are serviced as a unit. DO NOT
disassemble BJ and drive axle.
REASSEMBLY
1) Coat shaft with light coat of grease. Wrap splines with
tape. Install BJ boot, bands and DOJ boot on shaft. Ensure correct
size boot is installed in proper location.
2) Boot bands must be installed so lever is pulled toward
rear of vehicle when band is tightened. Pack proper amount of grease
in BJ and BJ boot. See GREASE APPLICATION table.
3) Place DOJ cage on shaft with smaller diameter installed
first. Install circlip, DOJ inner race, and snap ring on shaft. Apply
grease to DOJ inner race and cage. Install balls into cage.
4) Apply proper amount of grease to outer DOJ race. Install
shaft into DOJ outer race. Apply proper amount of grease to DOJ outer
race and install circlip. See GREASE APPLICATION table.
5) Place DOJ boot over DOJ outer race. Install boot bands so
lever is pulled toward rear of vehicle when band is tightened. Adjust
DOJ boot bands to have proper distance between centerline of boot
bands. See BOOT BAND SPECIFICATIONS table. This distance is necessary
to control air in DOJ boot. Tighten boot bands.
6) Install boot protector and band. Install dust cover on
shaft. Use a pipe with O.D. of 2.68" (68.0 mm), wall thickness of .09"\
(2.3 mm) and with overall length of 6.70" (170.1 mm) to install dust\
cover.
GREASE APPLICATION









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Application Ozs. (g)
BJ Boot
Montero
3.0L Engine .................. 4.6 (130)
All Others .................... 3.9 (110)
DOJ Outer Race
Montero
3.0L Engine ................... 2.3 (60)
All Others ..................... 1.9 (55)









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BOOT BAND SPECIFICATIONS








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Application In. (mm)
All Models .......... 3.03-3.27 (76.9-83.0)









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DIFFERENTIAL DISASSEMBLY
1) Remove differential carrier from vehicle. See DIFFERENTIAL
CARRIER R & I in this article. Remove cover. Mark bearing caps for
reassembly reference. Remove bearing caps. Remove differential case
assembly from carrier.
CAUTION: Ensure adjusting spacers, bearing caps, gears and side
bearings are marked for reassembly reference. Components

1) Install drive pinion in differential carrier. Install
spacer, pinion front shim(s) and front pinion bearing. DO NOT install
oil seal at this time. Install pinion flange, washer and retaining
nut. Check pinion rotating torque without pinion oil seal.
2) Recheck rotating torque. Rotating torque must be within
specification. See PINION ROTATING TORQUE SPECIFICATIONS table. Adjust
rotating torque by replacing drive pinion front shims or spacer. Once
correct rotating torque is obtained, install oil seal. Coat seal lip
with grease.
3) Install pinion flange so alignment marks are correct.
Apply light coat of grease to flange washer contact area. Install new
retaining nut. Check pinion rotating torque with pinion oil seal
installed. Rotating torque must be within specification. See PINION
ROTATING TORQUE SPECIFICATIONS table.
SIDE BEARING
1) Using Bearing Installer (MB990802-01), install bearings o\
n
differential case. Select 2 side bearing adjusting shims thinner than
those removed. Shims must be equal thickness on both sides. Install
shims on each side of case assembly. Install case assembly in
differential carrier.
2) Push case assembly fully to one side of carrier. Using 2
feeler gauges, measure clearance between carrier and side bearing shim
at opposite sides of bearing. Remove shims from one side of
differential carrier.
3) Measure thickness of shims removed. Add removed shim
thickness and 1/2 of feeler gauge clearance measurement plus .002" (.
05 mm). This is thickness of shim that should be installed on each
side of case. Select proper shims. Install equal shims on each side of
case assembly.
NOTE: Ensure no clearance exists between gear carrier and
adjusting shim.
4) Install side bearing shims and differential case assembly
in differential carrier. Using brass drift, tap shims to fit them to
side bearing outer race. Install bearing caps. Check ring gear
backlash.
RING GEAR BACKLASH
1) Lock drive pinion in place. Using dial indicator, check
ring gear backlash at heel of ring gear tooth. Measure at 4 locations
of ring gear. Gear backlash must be within .004-.006" (.10-.15 mm).
2) If not within specification, change side bearing adjusting
shims and recheck backlash. If backlash is too small, install thinner
shim behind ring gear and thicker shim opposite ring gear.
3) If backlash is excessive, install thicker shim behind ring
gear and thinner shim opposite ring gear. Check gear tooth contact
using paint impression method.
CAUTION: When changing shims, total thickness of all shims must
remain constant.
RING GEAR RUNOUT
Using dial indicator, measure runout at back side of ring
gear. Runout must be within .002" (.05 mm). If runout is excessive,
change ring gear-to-differential case mounting position. Recheck
runout. Install cover and gasket.

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DRIV E A XLE - R EA R N O N-IN TE G RAL
1991 M it s u bis h i M onte ro
199192 DRIVE AXLES
Differentials & Axle Shafts - Rear Non-Integral
Mitsubishi: Montero, Pickup
DESCRIPTION
Rear axle features a rigid banjo-type housing with semi-
floating axle shafts. Differential consists of hypoid reduction gears
and straight bevel differential gears. Limited Slip Differential (LSD)\
is available on all models.
AXLE RATIO & IDENTIFICATION
Ratio is determined by dividing number of ring gear teeth by
number of drive pinion teeth.
AXLE RATIO SPECIFICATIONS









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Application Ratio
Montero .................................................. 4.63
Pickup
2WD w/Light Suspension ................................. 3.91
2WD w/Heavy Suspension ................................. 4.22
4WD .................................................... 4.22









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LUBRICATION
CAPACITY
REAR AXLE GEAR OIL CAPACITY








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Application Pts. (L)
Montero .................................. 5.4 (2.5)
Pickup
Conventional
2WD ................................... 3.2 (1.5)
4WD ................................... 5.5 (2.6)
LSD .................................... 5.5 (2.6)









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FLUID TYPE
Conventional differentials use API classification GL-5 SAE
80W or 90W. Limited slip differentials use Mitsubishi Gear Oil
(8149630 EX) or Mopar Gear Oil (4318058) and Mopar Friction Modifier\
(4318060).
TROUBLE SHOOTING
DRIVE AXLE (RWD) TROUBLE SHOOTING








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PROBLEM
Possible Cause Action

Thrust washer must be changed to obtain correct specification. Correct
clearance is .002-.008" (.05-.20 mm).
10) Select thrust washers to obtain correct clearance from
pressure ring face and end of thrust washer surface. Thrust washers
are available in 3 sizes.
11) Apply gear oil and friction modifier to all components.
Install components in differential case. Ensure assembly order and
direction of clutch components are correct. See Fig. 9.
Fig. 9: Limited Slip Differential Assembly
Courtesy of Chrysler Motors.
12) Install differential case cover with reference marks
aligned. Tighten screws to specification in several steps. See TORQUE
SPECIFICATIONS table at end of article. Ensure cases contact each
other completely when fully assembled. Check for incorrect clutch
assembly if gap exists.
13) Using Clutch Plate Preload Tool (MB990988), Shaft
(MB990989) and torque wrench, measure starting torque. Slightly rotate\
unit before measuring starting torque. See Fig. 10.